Method and apparatus for mounting filament wire



Jan. 26, 1954 J. FLAWS, JR 2,667,189

METHOD AND APPARATUS FOR MOUNTING FILAMENT WIRE Filed April 20, 1950 Inven'i'or': John FLaws J1". b8 W( 1 H5 Alrlrorneg.

Patented Jan. 26, 1954 r METHOD APPARATUS FOR MOUNTING FILAMENT VJIRE John Flaws, Jr., East Cleveland, Ohio, assignor to General Electric Company, a corporation of New York Application April 20, 1950, Serial No. 157,050 7 Claims. (01. 140-711)) My invention relates to the manufacture of photographic flash lamps, electric incandescent lamps and similarly constructed devices having a filamentary wire mounted between a pair of current-carrying conductors. My invention relates to a method and apparatus particularly adapted to automatic forms of operation wherein a filamentary wire is presented at mounting rela tion to a pair of conductors, for instance, the conductors extending from a vitreous stemand wherein said filament wire is attached to said conductors, for instance, by working portions thereof over the filament wire. The invention is of particular advantage in the mounting of a straight length of an extremely fine wire having little strength between juxtaposed end portions of a pair of conductors, thereby enabling use of the filament mount on low energy electrical circuits of both low current and low voltage.

My method and apparatus are an improvement of the general method and apparatus disclosed in my United States Patent 2,327,033 which issued August 17, 1943, and which is assigned to the assignee of the present invention.

.One object of my invention is to provide an improved method and apparatus for the automatic mounting of an extremely fine wire on a pair of conductors, the method and apparatus being characterized by an ability to present a length of filament wire in mounting relation to the conductors and to attach said filament wire to said conductors in a satisfactory manner without injury to the filament wire.

The invention provides a method of arranging the filament at mounting relation to the conductors which eliminates the possibility of misalignment therebetween caused by inaccuracies of operation efiected by normal variations in apparatus. The invention also affords a manner of attaching the filament to the conductors which obviates the many difficulties of making a low resistance connection to an extremely fine wire of relatively little strength.

Another object of my invention is to provide a method and apparatus capable of innumerable cycles of operation in a satisfactory manner without appreciable variation and without development of more than a moderate amount of wear in the apparatus. Th invention has particular reference to the manner and means of arranging a filament wire at an accurate relation to conductors and of working portions of the conductors to cause them to grip the filament wire.

And still another object of my invention is to provide apparatus particularly adapted to efiect the mounting of fine wire having sufiicient springiness and curl to move by elastic reaction out of its lie in the usual mounting apparatus so as to interfere with the operation thereof. My apparatus provides means for withdrawing wire from a supply spool and attaching the withdrawn Wire to a pair of conductors in successive cycles of operation without manual attention. Generally speaking, my invention relates to a method and apparatus wherein a length of filamentary wire is first arranged adjacent to portions of a pair of conductors and is then advanced into hooks or below lips in the conductors by a relative motion therebetween in a direction parallel'to the extent of said conductors. Also preferably included within the invention is means for advancing the filament wire from a main supply thereof and means for holding and for retaining control over the free end of the main supply developed in each cycle of operation so as to assure successive cycles of operation without rethreading said wire in said means.

Still other objects and features of the method and apparatus of my invention will appear in the detailed following description and in the drawing. a

In the drawing, Fig. l is a composite side elevation showing a roll in the course of working notches and lips on conductors extending from a vitreous stem, View A being at slightly less than normal scale, and view a being at a greatly enlarged scale and showing only a portion of said roll and said conductors; Fig. 2 is a similar composite side elevation showing the stem and-filamentary wire at the moment of arrangement of said filament wire at mounting relation to the, conductors and showing the knives and the hold-,

ing and feeding jaws for the filamentary wire, view B being at the reduced scale and at a right angle to Fig. l, and View 17 being at the enlarged scale and at the same angle as Fig. 1 and showing only a portion of one conductor and the fila- V mentary wire; Fig. 3 is a similar composite side elevation of the stem and filamentary wire at the moment said filament wire is secured to the con-' ductors by the clamping jaws, Views C and 0 being at the same angle as Fig. l and at the same scale as respective views thereof; and Fig. 4 is a perspective view of the essential means for advancing the filamentary wire to mounting relation to the conductors of the stem, the means being shown for clarity as spaced abnormally along the length of the wire. 7

For a complete understanding of the method and apparatus of the invention, reference is made to the accompanying drawing and the disclosure of my United States Patent 2,327,033, dated I operativerelation to a.

roll l-intheillustration of inch and inso tube 4 comprising the stem 5. The sharp edge about the periphery of the rollforces COITBSpOl'ltling grooves or notches 6 in the conductors 2-and 3 and develops corresponding;projections or; lips I overhanging said notches i e dse cl nsuqt s 2 and 3. A metal block 8 prevents the conductors 2 and 3 from being pushed aside by the roll I which is moved in a manner duplicating the The.-

operation of the roll in my Patent 2327;83 -v stem 5 is supported by movable means, not shown in the present disclosure but preferably apart. ofjone of the heads of anconveyorl asshown in the .,aforesa id, patent which conveyor advances said stem '5 toasuccession of work. stations, in. turn and,. 'accordf gly, advances said stein its. mechanism of which the a part. However, the I the present invention has opposite faces of the edge at approximately- 4Q degr ees to each otherfand at a mean angle of approximately 45Tdegree's to the vertical, positionof lthe conductors 2 I and; 3 and, accordingly, forces metal fromisaid conductors lips] projecting laterally therefrom. The roll I shown is causedto penetrate conductors 2 ,-and 3 (of adiameterof .OZO inch) to a depth of .007

roll I and theblock 8. are

.005 'inch' width alongthe facevof said conducr la d-.

The, succeeding operations of I the method; occur at a work station separated fromtheinot hi ingrmeans, andto which. the stem 5 1 is. radvanoec in:turn.by its support means. work station, apparatus, is provided for filament: wire 9 at. mounting. relation .to. the .0031? ductors] and 3. Theifilament wires.- is held: acrossthe conductors 2 nected to. the main supply and while stretched tautbetween the frictionblocks I l andthelwirerfeedingjawsl2 and: I3.- so as.

and 3 while it is still coni G and to U lie in. a straight line as illustrated diagrammaticonductors 2-and 3 in 2 and 3so as toform I doing develops notchesiehaving a At this succeeding.

holding cally Fig, 4. A painot wire-holdingejawshi and l5-also=grip an intermediate section ottheend portion of the .filament wire 9 andassist I in fixing the position thereof. The friction -b1ocksl0 and H; the wire-holding jaws I iandlEjand thewire-feeding jaws l2 and I3 are arranged in the-present instance at an elevation to pes the filament wire 9 against portions of-the conductors 2 and 3 spaced from the overhanging lips- I in the manner shown at B and b in Fig. 2 Some variations can exist in the elevation taken by the stem 5 at this work station becausethe stem-supporting conveyor heads, herein represented only by thejaws l 6 and H, are not capable of being positioned with the; desired accuracy; 7 and, accordingly, the exact position-taken bythe filament wire 9 along the wires 2 and 3 is not thesame in succeeding cycles ofoperation. It has been established, in one instance, that ii the paratus is adjusted pl cee lem ntw re. 9 normally .020 als pndi n i id filamen r illeliva si pa-:

1 separates that; portion; of

V, ,4 said lips I and satisfactory operation can be ex pected under all normal conditions.

The next step in the cycle of operation occurs when the anvil I8 is moved up against the lower ends of the conductors 2 and 3 and pushes the stem 5 and said leads 2 and 3 upward sufiiciently to cause/the filament wire-9;- to-, efiec t, slide into-andfinally rest at thebase of the notches 6 as shown in dotted lines in b, Fig. 2. The upward motion of the anvil l8 slides the stem tube 4 upward through the jaws I6 and ii and moves the-conductors? and-3 sufficiently to carry the filament wire 9 completely to the base of the notchesfiqunder all conditions and variations usually.,-encountered-5and usually causes the conductors 2 and .3;Ito.pu11 said filament wire 9 upward from its normal straight lie opposite the ends of the wire-feeding jaws l2 and I3. Any slight;,.increase in tension created in the filament wire 9 does not result in injury thereto even thoughv saidrwirefiis-often .000? inchor lessg-in diameter. The apparatus for effecting; mes/s mentof the anvil lfiis-the positioningslide l il ofr clamping means .providing; for the p forcingot the lips 1 down against the-filament wiret -and thes the manner disclosed; at 2C- andc, Fig. 3., Theanyil I8;is;mounte d;at; a fixed: height abovethe slide ;l9on-' thebrackfiLEF-z ex-v tending from the top surface, thereof and: takesi .the controlled. upward; motion thereof; occurring,

in the firstpartof the next, iunctionofthezrapr paratus.

After, the filament wirefizis, located at; the: base; of the notches; 5; in the conductorsiz-sand- 3, their. 'iare bent over .onto the filament; wire 9; by: the; closing action oi two clamping. blocks 2i and". 22, '(C, Fig. 3), whichmovein against both..con.-. ductors 21anda3 from oppositesides;v The motion of clamping blocks-2] and:22- .correspond to that. of; similar-.means disclosed-in my-prior. Patent 2,327,033 and-is preferably created by. mounting said clamping blocks 21 and 22 uponjaws pivoted upon the vertically movable positioning slide 9in the manner ofthe means in said: patent. The conductors 2 and Sara engagedby projecting portions23 and ZlLof the clamping blocksil and-22*,

respectively, which portions have fiat-endsurfaces not easily-deformedinthecourse of theoperation' ofthe apparatus and which are; accordingly, capable of-goperating in a--uniform-manner for eXtended'periods-of time; The -flat endsurfacesof the projecting end portions 23 and- 24 of the clamping blocks 2 land2-2-effect a slightreduction inthe thickness oi and 3' and' press thelips I tightly against; the main body thereof with sum cient force ;to make a tight andsecure connection-to the filamentwire 9. The manner ofconnecting theconductors-2' and 3 andfilament wire {together is such astoi avoid possible injury to the filament wire 9 "and; to provide, uniformly low resistance connections therebetween'. The apparatus can .thereforebe.

used to mount the smaller size filament wires .0007. inch or less in diarneter andrmake mounts suitable for'useonveryilow, volt and low current'circuits. Withdrawal ,of the. clampingblocks 2 I and '22 and ltheanvil l8'occurs immediately after, the closing movement. of said clamping blocks. v

. The final step in the. manufacture of the mount occurswhen the .circularknives...2 5, and 25, which, are located adjacent conductor 3, arerotated so. astocause the coacting edges2l and, 28;to close on the, filament wire Band cut it. This operation, the filamentwire l.

the conductors 2 connected to the conductors 2 and 3 from the main supply thereof and in so doing develops a I new end on said supply opposite the knives 25 and 26. Inasmuch as the wire-feeding jaws I2 and I3 and the knives 25 and 26 are spaced from the conductors 2 and 3, a considerable excess of ing from conductor 2 to the wire-feeding jaws I2- and I3, as shown at B, Fig. 2. At the conclusion of the cutting operation, the wire-feeding jaws I 2 and I3 are opened to release the filament wire 9 attached to the conductors 2 and 3 from all contact with the apparatus. The operation of mounting the filament wire 9 is now complete and the mount held by stem 5 has only to be removed to complete the cycle of operation.

The filament wire 9 which has been mounted upon the stem 5 in the course of the above-described operations actually starts through its cycle of operation prior to the moment when the knives and 26 are operated, at which time the cooperating faces 29 and 39 of the holding jaws I4 and I 5 close upon that portion of the filament wire 9 which becomes the free end thereof after operation of said knives 25 and 26. The function of the wire-holding jaws I4 and I5 is to prevent the newly created end of the filament wire 9, which is relatively springy, from curling outward from its normal lie so that said end can be readily picked up and fed in the immediate operating interval of the apparatus. The wire-holding jaws I4 and I5 are arranged to turn about a common axis through the center of the hollow shaft 3| and the solid shaft 32 which are the respective supports for said holding jaws I4 and I5 and are shaped so as to extend around the boss 33 on the end surface of bracket 34 which boss 33 holds the corresponding hollow and solid support shafts 3i and 32' for the knives 25 and 26. The shafts 3I and 32 extend through the full width of the bracket 34 and provide for the operation of the wire-holding jaws I4 and I5 in much the same manner as the shafts 3I and 32 provide for the operation of the knives 25 and 26. Vertical movements of a rod 36 connected to the shafts 3I and 32 through the links 37 and 38 and the arms 39 and 40 provide the means of operating the holding jaws I4 and I5 at the proper moments from a central controlling means (not shown). At the presently referred to moment, the wire-holding jaws I4 and I5 are held in a closed position by the helical spring 4I extending between spring posts in the upper end of both jaws.

The operation of advancing the filament wire 9 to mounting relation in the apparatus is eifected by the wire-feeding jaws I2 and I3 which are shifted from the position shown to a gripping relation to the end portion of the filament 9 by a counterclockwise (Fig. 4) movement of the operating arm 42. The movement of the arm 42 is transferred to the sub-slide 43 through engagement with the roller 44 on pin 45 projecting from the side thereof and advances said jaws I2 and I3 when the base of the slot 46 in said sub-slide 43 engages the stud 41 and advances the main slide 48. The jaws I2 and I3 are pivoted upon the pins 49 and 50 projecting from the forward end portion of the main slide 48 which is located within ways in the bracket 5| and at the moment of advance are spaced apart at their forward nib ends 52 by the pressure of two studs 53 and 54 against their angular back portions55 so that.

said nib ends 52 passabove and below the co-, operating wire-gripping faces 29 and of the wire-holding jaws I4 and I5. The nib ends 52 of the wire-feeding jaws I2 and I3 advance to positions between the holding jaws I4 and I5 and a fixed guide 56-adjacent the friction blocks IO-and I Iland then close upon said wire 9 under the in fiuence of a return clockwise movement of the operating arm 42 which shifts the subslide 43 with respect to the main slide 48 sufficiently to carry the studs 53 and beyond the back portions 55 of said jaws I2 and I3 and a portion of.

pin 45 into a wedging position against corresponding angular inner faces 51 (only one face. partially shown) of said jaws I2 and I3. Longie tudinal movement does not occur in thejaws I2. and I3 at that particular moment as the limited movement of the operating arm 42 is only sufficient to reposition the subslide .43 within the main slide48. Friction produced by the spring pressed gib 58 against the topedge .of the main slide 48 holds it and the feeding jaws I2 and I3 in place at such times. Now that the end portion of the filament wire 9 is held by the wire-feeding jaws I2 and I3, the holding jaws I4 and I5 are opened by an upward movement of'the operating rod 36 which transfers motion to the support shafts 3| and 32 therefor through actuation of the links 31 and 38 and the arms 39 and 46. Said wire-feeding jaws I2 and I3 are then caused to move to the right (Fig. 4) to the position shown. The operation means for the rod 36 corresponds to similar means for actuating the knives 25 and 26 and'many other actuatingmeans common to lamp-making apparatus which means alford timed and otherwise controlled actuation of the various elements thereof. The movement of wirefeeding jaws I2 and I3 pulls additional filament wire 9 from the main supply thereof (not shown) and advances it between the friction blocks I0 and II, through the guide 56, between the open holding jaws I4 and I5, through the open notch in the circular knives 25 and 26 and finally to a position opposite that taken by the conductors 2 and 3, the position shown in Fig. 4. The actual relation of'the feeding jaws I2 and I3 to the knives 25 and 26 and the holding jaws I4 and I5, which are closed immediately after the wire 9 is advanced, appears as shown at B in Fig. 2 in the instance described when the wire-feeding operation is complete. These feeding and jaw-closing operations are the final operations in the cycle performed by the described apparatus, a cycle of which is repeated each time a stem is advanced into operative relation thereto.

Although a preferred embodiment of the invention has been disclosed, it will be understood that the invention is not to be limited to the specific construction of the parts shown but that said parts can be modified within the spirit and scope of the invention as defined by the appended claims.

What I claim as new and desire to secure by Letters Patent of the United States is:

1. The method of mounting a filament wire upon spaced metal conductors eachconductor 1 having a laterally projecting lip, which comportion of the filamentwireon theopposite sid I jaws and beyond said cutting means. positio i wire portionsgandi-the:-.adjacent ,condiictor;spor tions to causethe filament wire to belattaehedi said conductors. v i

2.v The method: of ,mounting.-..a filamentjwires upon. spaced-metal; condnctora extending. from, a stemwnich comprises. working .eash. e nductet, o. develop vadiagonaL notch witn aj. protrud ip,-

I of, comprising wire-holding jaws adapted; tQgPQ-LH riodically grip and therebyiposition'. the end pore...

tion on the filament .wire, cutting. means located;

adj acent the wire-holding .jawseand .the. end ,of

i the filament: wire, leadesupporting meanslocated;

adjacent the .cuttingsmeans .and beyond .t he,e of the filament wire, movablewire-feeding jaws; mounted in a plane normal .tothei plane of said wire-holding jawsandadapted ..t.o.:.grip the end of-theholding jawsnfrom the cuttingmee is. and; to advanceit longitudinallyhetween saidh l for: engagement withzportions of .the conductors; adjacent the-lips, means .-for moving said :wire- 3 feeding-jaws as aforesaid,-.means.for-efliegtinga relative movement thenconductors andz he feeding :jaws to causeethe filament wire to slide; v

along the -conductors- -to.positions belQW the lips clamping means-located adjacent the conductor; -1 supporting means for..- pressing the, lips tightly against thefilamentswire andthe conductors to cause saidfilament :Wire. to be attached thereto, and rneans for' actuating. the; cutting: means and j wire attached to the conductors from; th appae ratus.

4. Apparatus for mounting. a f l a nent w re upon spaced metal conductors exl f iiiin h9g a stem, each conductonhaving 1a.;lip o ect ng eo laterallyfrom the sidethereof; comprising w re-v holding jaws adaptede to .periodicallyg i a d thereby position the eendizportion of the filament wire,- cutting..means located adjacent :the wires.

holding jaws and the, endof'the fila ent Wit? 5 stem-supporting meansi. located adjacent the cutting-means and'beyond the end of thel-f lament wire-movable wire-feeding jawsmounted; in a plane normal tothe plane of said wirehold ing jaws and adapted to grip the end -por,tion. of the filament wire on the opposite side. of the holding jaws from the cutting means and-to. advance it longitudinally between said holding jaws and beyond said cutting means in positionfor engagement with portions of the condnctors adjacent'the li-ps, meansxfor moving s feeding jaws i asaforesaid,-:. movable-me jor effecting movement of theristem in, the. supp means to cause the filament .wire to slidealong; the conductors to positions belowthelips;clamps] ing means located adjacent theconductoresupe. porting. means f or V-pressing the lips tightly. against; the filament wire and: the; conductors to caus saidfil m w re t e i j, to; and means for actuating theouttingemeansn iQJ Pe-mnatheieeding; iawsito release thefila-L s ligwi ei-attached to; the. conductors from the nn tatus.

5, Th j l ethod-:oi-seouringra. filament. to a ,pair; -.of spa.ced-, generally .parallel .lead-in cone dllQtQl SlVh-iQh comprises. forming. in correspond'ng; sides. :of, said iconductors, projections extending laterallyirom theconductors and laterally ot the. plane including said conductors, holding,taut ;a. length of filament wire by gripping it at points. spaced, apart. a distance greater than. thespacing. oil. said. conductors, bringing said filament and, conductors into firm engagemcnt andiwith thefilament extending across the said; v corresponding, sides of. the conductors at 'pointsltherealong, spaced. slightly vaway from the said;.ip oje ctions and .then 'eilecting. a relative movement, 50f .jsaid. .filament...-and conductors in a direction to cause the filament to. slide along the. conductorsand. into. firm; engagement. with thesaid. projections, andnnall pressing said projections, against the main body of the .conductors to.clam the filament thereto.

6...Apparatus' forsecuring a'filain'ent to a pair ofyspaced, generally. .paraliel. lead-in conductors extending. froinastem. and having projections extendingv laterally from. corresponding sides thereofandlaterally of the plane including said conductors .and comprising, gripping means constructedand-arranged to grip a length of filament. at points spaced apart adistanc'egr'eater thani.the.spacing .of said conductors, support means .to. support said stem, means. mounting said grippingineans and said holder means for relative-movement ina-direction to bring said filament. and. conductors into firm engagement and with. the-filament extending across the said corresponding sides of: the conductors at points therealong .spacedsliglitly awayfrom -said projections,. means for efiecting the said relative movementpfssaid gripping means and holder means meansoperablesubsequent to the said relative movement. or"- .said gripping means and holder means to efiect relative movement of said conductors and filament in. a Y direction to cause the .iilament to slide along sthe conductors and into firm engagement with the said projections, and means operable .to clamp said projections against thewrnain body ofthe conductors to secure the filament thereto.

'7. Apparatus for securing a filament to a pair of spaced, generally parallel lead-in conductor extending from sa stem and 'havingpr'ojections extending later-ally. from corresponding sides thereon. andlaterally of v the plane including said conductors and comprising gripping means-constructed and arranged" to grip a leng thof filament at points spaced apart a distance greater thanflthe spacing of said. conductors, support means-to support said stem, means .moun'ting said gripping means and said; holder means for relative movement in a direction to bring said filament and conductors into firm engagement and -withthei filamentiextending across the said corresponding sides not the-conductors at points therealong spaced slightly away fromsaid projections," means for-effecting the said relative movement of said gripping .means and holder mean s means operablelsubs equent tothesaid relative-movement of 'said gripping means and holder means to effect longitudinal relative movement of said-conductorsin a direction to cause the filament to slide. along the conductors and-into firm engagement with-the said projections nd means operable to elampsaid-projec- JOHN FLAWS, JR.

References Cited in the file of this patent Number UNITED STATES PATENTS Name Date Schroter Jan. 9, 1912 Number 10 Name Date Higgins Nov. 1, 1927 Ledig July 28, 1931 Flaws May 9, 1933 Conn Aug. 1, 1933 Geiger July 23, 1940 Flaws Aug. 17, 19 3 Hayes Nov. 23, 1948 Quinn June 7, 1949 

